United States Patent (19) 11 3,966,993 Luck (45) June 29, 1976

54 PROCESS FOR MAKING SOLID SAUCE 3,300,319 111967 Marotta et al...... 99/ 144 BAR 3,652,299 31 1972 Penton...... 99/l 44 75 Inventor: John V. Luck, Lakewood, Ohio Primary Examiner-Jeanette M. Hunter 73) Assignee: SCM Corporation, New York, N.Y. Attorney, Agent, or Firm-Richard H. Thomas 22 Filed: May 20, 1970 (21) Appl. No.: 39,183 57 ABSTRACT 52 U.S. Cl...... 426/589; 426/652 A process for making a solid sauce bar by mixing fat 51) : Int. Cl.'...... A23L 1/40; A23L / 195 flour and , tempering the mixture, and sub 58 Field of Search ...... 99/144, 123; 426/589 sequently casting and cooling the bar until it is stable 56) References Cited at room temperature. UNITED STATES PATENTS 3 Claims, No Drawings 2,168,360 8/1939 Musher. 99/144 X 3,966,993 1. 2 derived, for example, from soybean oil, cottonseed oil, PROCESS FOR MAKING SOLID SAUCE BAR peanut oil, lard, tallow, and palm oil. The fat must have a Wiley melting point within the This invention relates to convenience sauce and range of about 100 to 125°F. and a minimum Solids gravy mixes, and more particularly to those that are a 5 Fat Index of 30% solids. The Solids Fat Index is the best solid bar form at normal room temperature and are described in the Official and Tentative Methods of the convertible on mixing with aqueous edible liquid into American Oil Chemists Society Coded CD 10-57 (re edible sauces, and to a process for making same. vised 1960, corrected 1961), for the development of Advantages of this sauce mix over pulverulent sauce the proper physical and palatability characteristics of mixes include convenience in handling, compactness, 10 the bar such as rigidity at room temperature and free ease of storage, and economy in packaging. Advan dom from tallow-like or waxy sensation in the mouth. tages of this bar over previously proposed sauce bars Softer and more plastic fats are not sufficiently resis include improved palatability and resistance to off-fla tant to deformation of shape at ordinary room tempera vor development, resistance to rancidity, and improved tures and are likely to yield bars that become pasty and 15 lose dimensional stability during shelf life or have a dimensional stability. The advantages of this sauce bar tendency to fat "bleed' on standing. can be obtained at less cost, as neither polysaccharrides Suitably, the fat component in the saucer bar has a nor a binder with a high percentage of water is re low Iodine Value, i.e. about 70 or less, and thus has quired. adequate resistance to rancidity over prolonged storage The bar of this invention has excellent storage stabil 20 periods. Additionally, the fat can contain minute ity, desirable appearance and gloss, good regidity and amounts of sequestering agents such as citric acid, and resistance to deformation at normal handling tempera anitoxidants such as butylated hydroxy toluene, propyl tures, and is easily converted into a sauce or gravy. The gallate, and nordihydroguaiaretic acid. sauces and gravies have desirable smooth consistency Small amounts, e.g. not more than about 15% basic and can be made with rich, well-developed flavors. My 25 weight of fat, and preferable about 0.1 to 5% on a process protects against loss of desirable appearance of similar basis, of edible emulsifiers advantageously are the bar in ordinary storage. incorporated with the fat in the sauce bar to assist in My sauce bar comprises an intimate mixture of the rapid hydration of the solids and conversion to a 40-60 parts of edible, tempered, emulsified triglyceride smooth, uniform sauce of good stability. These emulsi fat having acyl radicals of preponderantly C-C, 30 fiers include monoglycerides-diglycerides, potassium chain length, having melting points of about 100 to oleate, lecithin, sorbitan esters offatty acids. Of these I 125F., and having sufficient solid fat at ambient room prefer lecithin and superglycerinated fats (40-45% temperature to permit molding and handling in bar monoglyceride, the balance predominantly diglycer form and 15 to 40 parts of farinaceous flour or starch, ide) because of their economy, bland taste, and easy and 5 to 45 parts of solids having particle 35 blendability with the triglyceride fat. size not substantially greater than about 30 microns. The balance of the basic bar consists essentially of My process comprises intimately mixing together the farinaceous flour and starch and condiment solids, that fat, farinaceous flour or starch, and condiment solids, is, , , sugar, extending and flavoring agents, tempering the resulting mixture in an agitated temper etc. Typical condiment solids include salt, sugar, mono ing zone until fat crystals are generated, forming the 40 sodium glutamate, toasted , white pepper, pow tempered mixture into a solid bar under conditions dered onion, powder, , , cayenne, precluding complete remelting of the fat crystals, and pulverized bouillon, powdered , powdered gar cooling the resulting bar until it is dimensionally stable lic, powdered mushrooms, cheese flavor, ground at room temperature. seed, tomato crystals, lemon crystals, corn syrup solids, The total fat content of the gravy bar must be about 45 non-fat dry milk solids, dried eggs or egg fractions, 40 to 60 per cent of the total bar weight so that the bar meat powder, fish powder, edible cellulose or cellulosic can be easily converted to a palatable sauce which is materials such as particulate crystalline cellulose hav readily pourable and of smooth consistency. Less than ing molecular weight of about 30,000 to 50,000 and about 40 weight per cent of the fat is insufficient to give 10-50 micron particle sizes, proteinaceous material unitary, blocklike stability for handling, and greater 50 such as hydrolyzed soya protein, and mixtures of the than about 60 weight per cent produces a greasy bar foregoing. Of course, certain types and combinations of yielding sauce or gravy that is not palatably desirable. these condiment solids are useful in producing spe Preferably, I use about 40 to 50 weight per cent of fat cialty sauces, such as mushrooms in mushroom gravy, to insure thorough wetting of the flour and produce a but I do not mean to limit myself in this manner. The sauce that has a good consistency with desirable palat 55 condiment solids must have particle size in their largest ability and appearance. dimension not greater than about 30 microns and pref I have found that certain fats are unsuitable for use in erably from about 20 to 25 microns to obtain surface my invention, because they tend to deteriorate on gloss on the bar and avoid a dull, unappetizing appear standing and convert to sauces that leave a soapy sensa ance. In addition, these small particles assist in achiev tion in the mouth. Lauric fats, i.e. glycerides containing 60 ing a smooth sauce that is nongrainy and thus has good a significant content of C and lower acyl groups, are palatability. of this type. Thus, I use the edible triglyceride fats that I use about 15 to 40 weight per cent, basis total basic have acyl radicals of preponderantly C6-C18. These bar, of edible farinaceous flour or starch, e.g. wheat, can be made or obtained to exhibit excellent shelf sta rice, or potato flour, vegetable or grain starch finely bility against soapy flavor development and produce 65 pulverized or modified, or mixtures thereof, to make a sauces that are smooth and agreeable to the taste. My bar for thick sauce or gravy. Use of greater than about hydrogenated domestic oils and fractions and mixtures 40 weight per cent of the farinaceous flour produces a thereof are suitable for this invention. They can be sauce which is hard to pour and becomes stiff and 3,966,993 3 4. curdy. If I use less than about 15 weight per cent of a smooth, nongrainy surface on the bar. Additionally, flour, starch, etc., there is not a sufficient proportion of such a bar resists the development of fat bloom, e.g. these solids present in the sauce to body the fat and change in fat crystal structure with concurrent greying obtain palatable thickening and supress a greasy oral of the bar surface, so that during storage it retains its quality of the resulting sauce. For best results, I prefer attractive surface appearance. to use about 15 to 38 weight per cent of the edible I prefer to temper the batch by cooling in an agitated farinaceous flour to form a non-oily product of agree tempering zone until fat crystallization gives the mix able consistency. thick, mushy consistency. The mix is then held at this The sauce bar can contain suitable liquid flavoring point for several minutes to allow the development of and colorings, in addition to the above-described food 10 stable fat crystals. Preferably, the tempering zone can solids, that are absorbed on the basic bar solids. These be maintained at a temperature range of about 10 to include caramel color, vegetable colorings, and various 20°F. below the melting point of the fat constituency of essential oils such as oil, oil, oil, the mix. After cooling, I then reheat the mix, being sage oil, wild oil, and oil. Furthermore, careful not to remelt all of the stable fat crystals in the for added body and flavor, and to produce a sauce or 5 mix to produce a bar resistant upon final cooling to gravy of home-made appearance, I can add bits or change in fat crystal structure. Reheating decreases the chunks of foodstuff such as dried mushrooms, minced thickness of the mush, so that it then can be poured onion, dried meat, and dehydrated vegetable foodstuff easily into molds and cooled to a final bar product. such as dehydrated carrots or potatoes. However, I can extrude the mush without reheating to The total moisture content of the inventive bar, in 20 form a bar or rod. The product can also be flaked, and cluding indigenous moisture of the ingredients such as the flakes compressed into bars, scored for division, condiment solids, flour, and food chunks, should not etc., but for compactness, ease of handling, and ease of exceed about 5 per cent of the total bar weight, and should be preferably not more than about 2 to 3 per packaging, I prefer casting it to a bar form. cent to maintain best storage stability and to resist 25 The following examples show various ways in which off-flavor development (which otherwise could de my invention has been practiced, but should not be velop by degradation or putrefaction of proteins, etc., construed as limiting the invention. The moisture con such as in meat or grain solids). The bar package can tent of all bars prepared was less than 5%. be permeable to atmospheric moisture, because the fat EXAMPLE 1 enrobing of the solids is effective in protecting them 30 from deleterious contact with ordinary atmospheric A brown gravy bar was prepared by melting at a moisture. temperature of 130°F., 10 parts of a hydrocottonseed My sauce bars are manufactured for ready conver fat having a melting point of 119°F., and a Solid Fat sion in aqueous liquid to appetizing sauces and gravies. Index of 45% at 70°F. and containing 0.4 parts lecithin, By aqueous liquid I mean to include water, milk, 35 and mixing this melted, emulsified fat with 13.10 parts cream, vinegar, wine, lemon juice, and syrup solutions. pulverized bouillon, 8.08 parts dextrin, 3.46 parts arti Reconstitution of the bar in these liquids can be ficial flavoring, 1.15 parts sugar, 1.15 parts caramel achieved most easily by warming the liquid to a temper color, 0.62 parts monosodium glutamate, and 0.31 ature substantially above room temperature and by parts . agitation of the sauce bar-liquid dispersion for a short 40 This fat-condiment solids mixture was blended in a time to develop full-bodied flavor of the sauce. Advan Hobart mixer until a uniform dispersion of the dry tageously, I use about one quart of liquid for 4 ounces ingredients in the molten fat was obtained. During the of sauce bar, but about 3 to 5 ounces of sauce bar per blending, the temperature of the blend was allowed to quart of liquid can be adequately used to prepare drop to 100°F. After blending, the mixture was passed sauces of differing pourability. 45 through a 3-roll refiner set at about 25 microns in the In manufacturing, I can grind all of the basic bar final nip, to reduce the particle size of the condiment condiment solids to the proper particle size, being care solids to below about 30 microns in their largest dimen ful to except the bits and chunks such as mushrooms, sion and to further coat with fat. The product was col onion, etc., which are added later. These ground solids lected and blended with 30.00 parts of the hydrocot then can be mixed into a portion or all of the melted fat SO tonseed fat described above, 28.80 parts flour, and and blended to a uniform batch. However, I prefer to 3.33 parts minced onion, the blending being done in a blend all of the condiment solids into a molten portion Hobart mixer until uniform, the mixture being heated of the fat, and mill this fat portion in a roll refiner to to a temperature of 130°F. during blending. comminute the solids present. The refining not only This final mixture was tempered by cooling to 105F. comminutes the condiment solids, but also contributes 55 with agitation until fat crystallization gave the entire to a more uniform product by intimately blending and mix a thick, mushy consistency. The mix was held at coating these solids with the emulsifier-containing fat. this point for several minutes to allow the development. To this fraction I then stir in the farinaceous flour, food of stable fat crystals. The mixture was then slowly chunks, if desired, and remaining melted fat to produce warmed up to a temperature of 114°F. at which point a uniform mixture of the basic bar ingredients. Alterna 60 the mixture was readily pourable, yet contained suffi tively, I can grind a blended fat-condiment solid mix cient fat crystals to seed the remaining molten fat. A ture in a hammer, rod, or ball type mill to achieve portion of the mix was then poured into a 1% ounce bar particle size reduction and mixing. mold and allowed to harden in a refrigerated cabinet After a molten batch is prepared, I must temper it held at 45°F. The resulting bar had good structural prior to further processing to form an initial thick mush 65 rigidity, excellent retention of bar shape, a glossy sur of stable fat crystals. By so doing, I induce the forma face, and resisted deformation at elevated tempera tion of stable fat crystals in the polymorphic fat that tures (100°F.). It was easily packaged by wrapping with contribute to a good gloss in the sauce bar and produce sheet material and stacked on a shelf for storage, many 3,966,993 S 6 bars being able to be stacked on top of one another and further blended with 30 parts of the hydrocotton without rigid separators. seed fat and 15.45 parts of arrowroot starch in a Hobart After one month of storage, the bar was removed mixer while heating to a temperature of 130F. during from the shelf where it had been stored at 100°F., and blending. examined. It retained its bar shape and glossy surface, This mixture was tempered, reheated, cast, and and there was no indication of fat “bloom' on the bar. cooled in the same manner as in Example 1. The result The bar was put in a pan with a cup of cold water, and ing mushroom gravy bar was rigid at normal room the water heated to boiling. In a short time, the bar temperature (72F.), had a glossy appearance, and melted, and the mixture was stirred and simmered for resisted deformation of bar form at elevated tempera one minute. The resulting gravy was then examined and 10 ture (100F.). The bar was easily packaged and several tasted. It had smooth consistency, rich flavor, no soapy such bars could be stacked one on another for storage or rancid flavor, was easily pourable, and had excellent at 100°F. After two months, the bar was examined and palatability with no waxy or tallow mouth sensation. found to have maintained good gloss and bar shape and A portion of the gravy was poured into a jar, and the had resisted fat bloom. jar allowed to cool at room temperature for 1 hour. The 15 jar was then capped and refrigerated at 40°F. for 24 The bar easily dispersed in water to yield a sauce hours. After this refrigeration, the contents of the jar prepared in a manner similar to the brown gravy pre were emptied into a pan and reheated to 160°F. with pared in Example 1. The gravy was rich and smooth, occasional stirring. The resulting gravy was then tested felt non-waxy to the mouth, had excellent flavor, and and poured, and it was found to be comparable in all 20 could be refrigerated and reheated without any notice respects to the gravy prepared initially by direct disper able loss in physical characteristics or palatability. sion of the bar in water. EXAMPLE 4 EXAMPLE 2. A chicken gravy bar was prepared by melting 10 An onion gravy bar was prepared by melting 10.0 25 parts of a hydrogenated beef tallow which had a melt parts of the hydrocottonseed fat described in Example ing point of 121°F. and a Solid Fat Index of 42% at 1 at 130F., and combining this melted fat with 7.56 70°F. and mixing this molten fat with 7.92 parts hydro parts pulverized bouillon, 5.05 parts granulated sugar, lyzed vegetable protein, 7.44 parts special chicken 2.76 parts salt, 2.52 parts powdered onion, 0.76 parts (monosodium glutamate, chicken, salt, monosodium glutamate, 0.51 parts powdered , 30 sugar, flavoring, malto-dextrin, chicken fat, hydrolyzed 0.51 parts caramel color, and 0.01 parts oleo-resin vegetable fat, , dextrose, and hydrogenated vege black pepper. table fat), 3.35 parts nonfat milk solids, 3.35 parts This fat-condiment solids mixture was then blended sugar, 2.55 parts salt, 2.60 parts powdered onion, 1.49 and milled in the same manner as the brown gravy parts dehydrated chicken broth, and 0.05 parts caramel fat-condiment solids mixture of Example 1. The prod 35 color. uct was collected and further blended with 30.0 parts This fat-condiment solids combination was then of the hydrocottonseed fat, 37.8 parts of flour, and 2.52 blended and milled in the same manner as the brown parts minced onion, in a Hobart mixer with heating to gravy fat-condiment solids combination of Example 1. a temperature of 130°F. during blending. The product was collected and further blended with This mixture was tempered, reheated, cast, and 40 30.0 parts of the hydrocottonseed fat, 29.76 parts of cooled in the manner of Example 1. The resulting flour, and 1.49 parts of dried chicken pieces in a Ho onion gravy bar was solid at room temperature, had a bart mixer while heating to a temperature of 130°F. glossy, nongrainy surface, and resisted slumping and The mixture was tempered, reheated, cast, and deformation of bar shape at 100°F. It was easily pack cooled in the same manner as the brown gravy mixture aged and withstood handling and stacking without 45 of Example 1. The resulting chicken gravy bar exhib breakage. ited good gloss and rigidity, and resisted slumping of The bar was stored, prepared as a gravy, and the bar bar shape at temperatures as high as 100°F. The bar and gravy examined in the same manner as in Example was wrapped and maintained at this temperature for 1. The bar retained its gloss, flavor, and rigidity, and one month, after which time it was found to have re there was not visual evidence of fat bloom on the bar 50 tained its original shape and good gloss with no visual surface. The gravy was rich, smooth, and non-waxy, evidence of fat bloom. and it contained bits of minced onion that gave added The bar was easily dispersed in boiling water to yield . The gravy was easily poured and could be refriger a rich gravy prepared in the same manner as the brown ated for repreparation, the gravy thus resulting being gravy of Example 1. This chicken gravy had good flavor similar in taste and physical characteristics to the origi 55 and no trace of off-flavor development, was easily nal gravy. pourable and produced no soapy taste or waxy sensa tion in the mouth. The gravy could be cooled, stored by EXAMPLE 3 refrigeration for several days, and reheated to produce A Hollandaise Sauce Bar was prepared by melting gravy having no noticeable loss in taste appeal or physi 10.00 parts of the hydrocottonseed fat described in 60 cal characteristics. Example 1 at 130F., and mixing the melted fat with 31.14 parts egg yolk solids, 5.78 parts nonfat milk sol EXAMPLE 5 ids, 5.36 parts salt, 1.71 parts citric acid, 0.55 parts A mushroom sauce mix was prepared by the process artificial lemon flavor, and 0.01 parts oleoresin black described in Example 1. The recipe for the mushroom pepper. 65 sauce was 6 parts melted hydrocottonseed fat, 3 parts This fat-condiment solids mixture was then milled in pulverized bouillon, 0.3 part of monosodium gluta the same manner as the brown gravy fat-condiment mate, 1 part salt, 1.4 parts sugar, 0.5 part powdered solids mixture of Example 1. The product was collected onion, 0.1 part white pepper, 0.5 part dry caramel 3,966,993 7 8 color, 2 parts powdered mushroom and 0.5 part ground microns; celery seeds. b. tempering the resulting mixture in an agitated What is claimed is: tempering zone until fat crystals are generated, 1. A process for making a sauce bar convertible on forming a solid bar of the tempered mixture under mixing with aqueous liquid into an edible sauce which conditions precluding complete remelting of said comprises: fat crystals; and a. intimately mixing together 40 to 60 parts of c. cooling the resulting bar until it is dimensionally melted, edible emulsified triglyceride fat having stable at room temperature. acyl radicals of preponderantly CCs chain 2. The process of claim 1 wherein said tempering is length and having a Wiley melting point of about 10 carried on at a temperature of about 100 to 110F. 100 to 125F. and a minimum of 30%. Solid Fat 3. The process of claim 2 wherein said tempered Index at 70F., and 15 to 40 parts of farinaceous mixture is cast into a mold and cooled until it is dimen flour, and 5 to 45 parts of condiment solids having sionally stable at room temperature. particle size not substantially greater than about 30 is ck k :: *k sk

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65 UNITED STATES PATENT AND TRADEMARK OFFICE CERTIFICATE OF CORRECTION

PATENT NO. : 3,966,993 DATED : June 29, 1976

INVENTOR(S) : John V. Luck it is Certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 5, line 19, change "tested" to -- tasted--.

signed and Sealed this Twenty-eighth Day of September 1976

RUTH C. MASON C. MARSHALL DANN it testing Officer Commissioner of Patents and Trademarks